Pipe Formality Evaluation for Expandable Tubulars

ABSTRACT

A method of testing a tubular member and selecting tubular members for suitability for expansion by subjecting a representative sample the tubular member to axial loading, stretching at least a portion of the tubular member through elastic deformation, plastic yield and to ultimate yield, and based upon changes in length and area calculating an expandability coefficient indicative of expandability of the tubular members and selecting tubular members with relatively high coefficients indicative of good expandability.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage patent application for PCTpatent application serial number PCT/US2003/025667, attorney docketnumber 25791.118.02, filed on Aug. 18, 2003, which claimed the benefitof the filing dates of (1) U.S. provisional patent application Ser. No.60/412,653, attorney docket no 25791.118, filed on Sep. 20, 2002, thedisclosures of which are incorporated herein by reference.

The present application is related to the following: (1) U.S. patentapplication Ser. No. 09/454,139, attorney docket no. 25791.03.02, filedon Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, attorney docket no. 25791.8.02, filedon Feb. 10, 2000, (4) U.S. Pat. No. 6,328,113, (5) U.S. patentapplication Ser. No. 09/523,460, attorney docket no. 25791.11.02, filedon Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patentapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635,attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S.provisional patent application Ser. No. 60/162,671, attorney docket no.25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999, (13) U.S. provisional patent application Ser. No.60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14)U.S. provisional patent application Ser. No. 60/159,039, attorney docketno. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patentapplication Ser. No. 60/159,033, attorney docket no. 25791.37, filed onOct. 12, 1999, (16) U.S. provisional patent application Ser. No.60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17)U.S. provisional patent application Ser. No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patentapplication Ser. 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No. 60/313,453, attorney docketno. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patentapplication Ser. No. 60/317,985, attorney docket no. 25791.67, filed onSep. 6, 2001, (28) U.S. provisional patent application Ser. No.60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001,(29) U.S. patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, (30) U.S. patent application Ser. No.10/016,467, attorney docket no. 25791.70, filed on Dec. 10, 2001, (31)U.S. provisional patent application Ser. No. 60/343,674, attorney docketno. 25791.68, filed on Dec. 27, 2001, (32) U.S. provisional patentapplication Ser. No. 60/346,309, attorney docket no 25791.92, filed onJan. 7, 2002, (33) U.S. provisional patent application Ser. No.60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002, (34)U.S. provisional patent application Ser. No. 60/380,147, attorney docketno. 25791.104, filed on May 6, 2002, (35) U.S. provisional patentapplication Ser. No. 60/387,486, attorney docket no. 25791.107, filed onJun. 10, 2002, (36) U.S. provisional patent application Ser. No.60/387,961, attorney docket no. 25791.108, filed on Jun. 12, 2002, (37)U.S. provisional patent application Ser. No. 60/394,703, attorney docketno. 25791.90, filed on Jun. 26, 2002, (38) U.S. provisional patentapplication Ser. No. 60/397,284, attorney docket no. 25791.106, filed onJul. 19, 2002, (39) U.S. provisional patent application Ser. No.60/398,061, attorney docket no. 25791.110, filed on Jul. 24, 2002, (40)U.S. provisional patent application Ser. No. 60/405,610, attorney docketno. 25791.119, filed on Aug. 23, 2002, (41) U.S. provisional patentapplication Ser. No. 60/405,394, attorney docket no. 25791.120, filed onAug. 23, 2002, (42) U.S. provisional patent application Ser. No.60/412,542, attorney docket no. 25791.102, filed on Sep. 20, 2002, (43)U.S. provisional patent application Ser. No. 60/412,487, attorney docketno. 25791.112, filed on Sep. 20, 2002, (44) U.S. provisional patentapplication Ser. No. 60/412,488, attorney docket no. 25791.114, filed onSep. 20, 2002, (45) U.S. provisional patent application Ser. No.60/412,177, attorney docket no. 25791.117, filed on Sep. 20, 2002, (46)U.S. provisional patent application Ser. No. 60/412,653, attorney docketno. 25791.118, filed on Sep. 20, 2002, (47) U.S. provisional patentapplication Ser. No. 60/412,544, attorney docket no. 25791.121, filed onSep. 20, 2002, (48) U.S. provisional patent application Ser. No.60/412,196, attorney docket no. 25791.127, filed on Sep. 20, 2002, (49)U.S. provisional patent application Ser. No. 60/412,187, attorney docketno. 25791.128, filed on Sep. 20, 2002, and (50) U.S. provisional patentapplication Ser. No. 60/412,371, attorney docket no. 25791.129, filed onSep. 20, 2002, the disclosures of which are incorporated herein byreference.

The present application is related to each of the following: (1) U.S.patent application Ser. No. ______, attorney docket number25791.121.______, filed on ______; and (2) U.S. patent application Ser.No. ______, attorney docket number 25791.129.______, filed on ______.

BACKGROUND OF THE INVENTION

The present invention relates generally to tubular steel well casing andmore particularly to an expansion mandrel which reduces stress duringexpansion of the casing.

Solid tubular casing of substantial length is used as a borehole linerin downhole drilling. The casing is comprised of end-to-endinterconnected segments of steel tubing to protect against possiblecollapse of the borehole and to optimize well flow. The tubing oftenreaches substantial depths and endures substantial pressures.

It is present practice to expand the steel tubing downhole by using amandrel. This is a cold-working process which presents substantialmechanical challenges. This technology is known as solid expandabletubular (SET) technology. This cold-working process deforms the steelwithout any additional heat beyond what is present in the downholeenvironment.

It is present practice to expand the steel tubing downhole by using amandrel. This is a cold-working process which presents substantialmechanical challenges. This technology is known as solid expandabletubular (SET) technology. This cold-working process deforms the steelwithout any additional heat beyond what is present in the downholeenvironment.

An expansion cone, or mandrel, is used to permanently mechanicallydeform the pipe. The cone is moved through the tubing by a differentialhydraulic pressure across the cone itself, and/or by a direct mechanicalpull or push force. The differential pressure is pumped through aninner-string connected to the cone, and the mechanical force is appliedby either raising or lowering the inner string.

Progress of the cone through the tubing deforms the steel beyond itselastic limit into the plastic region, while keeping stresses belowultimate yield. Expansions greater than 20%, based on pipe ID, have beenaccomplished. However, most applications using 4¼-13⅜ inch tubing haverequired expansions less than 20%. The ID of the pipe expands to thesame ID of the expansion mandrel, which is a function of expansionmandrel OD. Contact between cylindrical mandrel and pipe ID duringexpansion leads to significant forces due to friction. It would bebeneficial to provide method for testing tubular members for suitabilityfor the expansion process. It would also be beneficial to provide amethod for selecting tubing or tubular members well suited forexpansion.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method of testing atubular member for suitability for expansion is provided using anexpandability coefficient determined pursuant to a stress-strain test ofa tubular member using axial loading.

According to another aspect of the present invention, a tubular memberis selected for suitability for expansion on a basis comprising use ofan expandability coefficient determined pursuant to a stress-strain testof a tubular member using axial loading.

According to another aspect of the present invention, a method oftesting a tubular member for suitability for expansion is provided usingan expandability coefficient determined pursuant to a stress-strain testusing axial loading comprising calculation of plastic strain ratio forobtaining the expansion coefficient pursuant to test results and usingthe formula: $\begin{matrix}{f = \frac{\ln\frac{b_{o}}{b_{k}}}{\ln\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 1}\end{matrix}$where,f—expandability coefficientbo & bk—initial and final tube area (inchˆ2)Lo & Lk—initial and final tube length (inch)b=(Dˆ2−dˆ2)/4—cross section tube area.

According to another aspect of the present invention, a tubular memberis selected for suitability for expansion on a basis comprising use ofan expandability coefficient determined pursuant to a stress-strain testusing axial loading comprising calculation of plastic strain ratio forobtaining the expansion coefficient pursuant to test results and usingthe formula: $\begin{matrix}{f = \frac{\ln\frac{b_{o}}{b_{k}}}{\ln\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 1}\end{matrix}$where,f—expandability coefficientbo & bk—initial and final tube area (inchˆ2)Lo & Lk—initial and final tube length (inch)b=(Dˆ2-dˆ2)/4—cross section tube area.

According to another aspect of the present invention, a tubular memberis selected for suitability for expansion on a basis comprising use ofan expandability coefficient determined pursuant to a stress-strain testusing axial loading and one or more physical properties of the tubularmember selected from stress-strain properties in one or more directionalorientations of the material, Charpy V-notch impact value in one or moredirectional orientations of the material, stress rupture burst strength,stress rupture collapse strength, strain-hardening exponent (n-value),hardness and yield strength.

According to another aspect of the present invention, a method formanufacturing an expandable member used to complete a structure byradially expanding and plastically deforming the expandable member isprovided that includes forming the expandable member from a steel alloycomprising a charpy energy of at least about 90 ft-lbs.

According to another aspect of the present invention, an expandablemember for use in completing a structure by radially expanding andplastically deforming the expandable member is provided that includes asteel alloy comprising a charpy energy of at least about 90 ft-lbs.

According to another aspect of the present invention, a structuralcompletion positioned within a structure is provided that includes oneor more radially expanded and plastically deformed expandable memberspositioned within the structure; wherein one or more of the radiallyexpanded and plastically deformed expandable members are fabricated froma steel alloy comprising a charpy energy of at least about 90 ft-lbs.

According to another aspect of the present invention, a method formanufacturing an expandable member used to complete a structure byradially expanding and plastically deforming the expandable member isprovided that includes forming the expandable member from a steel alloycomprising a weight percentage of carbon of less than about 0.08%.

According to another aspect of the present invention, an expandablemember for use in completing a wellbore by radially expanding andplastically deforming the expandable member at a downhole location inthe wellbore is provided that includes a steel alloy comprising a weightpercentage of carbon of less than about 0.08%.

According to another aspect of the present invention, a structuralcompletion is provided that includes one or more radially expanded andplastically deformed expandable members positioned within the wellbore;wherein one or more of the radially expanded and plastically deformedexpandable members are fabricated from a steel alloy comprising a weightpercentage of carbon of less than about 0.08%.

According to another aspect of the present invention, a method formanufacturing an expandable member used to complete a structure byradially expanding and plastically deforming the expandable member isprovided that includes forming the expandable member from a steel alloycomprising a weight percentage of carbon of less than about 0.20% and acharpy V-notch impact toughness of at least about 6 joules.

According to another aspect of the present invention, an expandablemember for use in completing a structure by radially expanding andplastically deforming the expandable member is provided that includes asteel alloy comprising a weight percentage of carbon of less than about0.20% and a charpy V-notch impact toughness of at least about 6 joules.

According to another aspect of the present invention, a structuralcompletion is provided that includes one or more radially expanded andplastically deformed expandable members; wherein one or more of theradially expanded and plastically deformed expandable members arefabricated from a steel alloy comprising a weight percentage of carbonof less than about 0.20% and a charpy V-notch impact toughness of atleast about 6 joules.

According to another aspect of the present invention, a method formanufacturing an expandable member used to complete a structure byradially expanding and plastically deforming the expandable member isprovided that includes forming the expandable member from a steel alloycomprising the following ranges of weight percentages: C, from about0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn, from about0.10 to about 1.92; P, from about 0.004 to about 0.07; S, from about0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, upto about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about 5.

According to another aspect of the present invention, an expandablemember for use in completing a structure by radially expanding andplastically deforming the expandable member is provided that includes asteel alloy comprising the following ranges of weight percentages: C,from about 0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn,from about 0.10 to about 1.92; P, from about 0.004 to about 0.07; S,from about 0.0008 to about 0.006; Al, up to about 0.04; N, up to about0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb,up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mb, up toabout 5.

According to another aspect of the present invention, a structuralcompletion is provided that includes one or more radially expanded andplastically deformed expandable members; wherein one or more of theradially expanded and plastically deformed expandable members arefabricated from a steel alloy comprising the following ranges of weightpercentages: C, from about 0.002 to about 0.08; Si, from about 0.009 toabout 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 toabout 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04;N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up toabout 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9;and Mo, up to about 5.

According to another aspect of the present invention, a method formanufacturing an expandable tubular member used to complete a structureby radially expanding and plastically deforming the expandable member isprovided that includes forming the expandable tubular member with aratio of the of an outside diameter of the expandable tubular member toa wall thickness of the expandable tubular member ranging from about 12to 22.

According to another aspect of the present invention, an expandablemember for use in completing a structure by radially expanding andplastically deforming the expandable member is provided that includes anexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

According to another aspect of the present invention, a structuralcompletion is provided that includes one or more radially expanded andplastically deformed expandable members positioned within the structure;wherein one or more of the radially expanded and plastically deformedexpandable members are fabricated from an expandable tubular member witha ratio of the of an outside diameter of the expandable tubular memberto a wall thickness of the expandable tubular member ranging from about12 to 22.

According to another aspect of the present invention, a method ofconstructing a structure is provided that includes radially expandingand plastically deforming an expandable member; wherein an outer portionof the wall thickness of the radially expanded and plastically deformedexpandable member comprises tensile residual stresses.

According to another aspect of the present invention, a structuralcompletion is provided that includes one or more radially expanded andplastically deformed expandable members; wherein an outer portion of thewall thickness of one or more of the radially expanded and plasticallydeformed expandable members comprises tensile residual stresses.

According to another aspect of the present invention, a method ofconstructing a structure using an expandable tubular member is providedthat includes strain aging the expandable member; and then radiallyexpanding and plastically deforming the expandable member.

According to another aspect of the present invention, a method formanufacturing a tubular member used to complete a wellbore by radiallyexpanding the tubular member at a downhole location in the wellborecomprising: forming a steel alloy comprising a concentration of carbonbetween approximately 0.002% and 0.08% by weight of the steel alloy.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts in a schematic fragmentary cross-sectional view along aplane along and through the central axis of a tubular member that istested to failure with axial opposed forces.

FIG. 2 is a stress-strain curve representing values for stress andstrain that may be plotted for solid specimen sample.

FIG. 3 is a schematically depiction of a stress strain curverepresenting values from a test on a tubular member according to anillustrative example of one aspect of the invention.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

One of the problems of the pipe material selection for expandabletubular application is an apparent contradiction or inconsistencybetween strength and elongation. To increase burst and collapsestrength, material with higher yield strength is used. The higher yieldstrength generally corresponds to a decrease in the fracture toughnessand correspondingly limits the extent of achievable expansion.

It is desirable to select the steel material for the tubing by balancingsteel strength with amount absorbed energy measure by Charpy testing.Generally these tests are done on samples cut from tubular members. Ithas been found to be beneficial to cut directional samples bothlongitudinally oriented (aligned with the axis) and circumferentiallyoriented (generally perpendicular to the axis). This method of selectingsamples is beneficial when both directional orientations are used yetdoes not completely evaluate possible and characteristic anisotropythroughout a tubular member. Moreover, for small diameter tubing samplesrepresentative of the circumferential direction may be difficult andsometimes impossible to obtain because of the significant curvature ofthe tubing.

To further facilitate evaluation of a tubular member for suitability forexpansion it has been found beneficial according to one aspect of theinvention to consider the plastic strain ratio. One such ratio is calleda Lankford value (or r-value) which is the ratio of the strainsoccurring in the width and thickness directions measured in a singletension test. The plastic strain ratio (r or Lankford−value) with avalue of greater than 1.0 is found to be more resistant to thinning andbetter suited to tubular expansion. Such a Lankford value is found to bea measure of plastic anisotropy. The Lankford value (r) may be calculateby the Equation 2 below. $\begin{matrix}{r = \frac{\ln\frac{b_{o}}{b_{k}}}{\ln\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 2}\end{matrix}$where,r—normal anisotropy coefficientbo & bk—initial and final widthLo & Lk—initial and final length

However, it is time consuming and labor intensive for this parameter tobe measured using samples cut from real parts such as from the tubularmembers. The tubular members will have anisotropic characteristics dueto crystallographic or “grain” orientation and mechanically induceddifferences such as impurities, inclusions, and voids, requiringmultiple samples for reliably complete information. Moreover, withindividual samples, only local characteristics are determined and thecomplete anisotropy of the tubular member may not be determinable.Further some of the tubular members have small diameters so that cuttingsamples oriented in a circumferential direction is not always possible.Information regarding the characteristics in the circumferentialdirection has been found to be important because the plastic deformationduring expansion of the tubular members occurs to a very large extent inthe circumferential direction,

One aspect of the present invention comprises the development of asolution for anisotropy evaluation, including a kind of plastic strainratio similar to the Lankford parameter that is measured using realtubular members subjected to axial loading.

FIG. 1 depicts in a schematic fragmentary cross-sectional view along aplane along and through the axis 12 of a tubular member 10 that istested with axial opposed forces 14 and 15. The tubular member 10 isaxially stretched beyond the elastic limit, through yielding and toultimate yield or fracture. Measurements of the force and the OD and IDduring the process produce test data that can be used in the formulabelow to produce an expandability coefficient “f” as set forth inEquation 1 above. Alternatively a coefficient called a formabilityanisotropy coefficient F(r) that is function of the normal anisotropyLankford coefficient r may be determined as in Equation 3 below.$\begin{matrix}{{F(r)} = \frac{\ln\frac{b_{o}}{b_{k\quad}}}{\ln\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 3}\end{matrix}$F(r)—formability anisotropy coefficientbo & bk—initial and final tube area (inchˆ2)Lo & Lk—initial and final tube length (inch)b=(Dˆ2−dˆ2)/4—cross section tube area.

In either circumstance f or F(r) the use of this testing method for anentire tubular member provides useful information including anisotropiccharacteristics or anisotropy of the tubular member for selecting orproducing beneficial tubular members for down hole expansion, similar tothe use of the Lankford value for a sheet material.

Just as values for stress and strain may be plotted for solid specimensamples, as schematically depicted in FIG. 2, the values for conductinga test on the tubular member may also be plotted, as depicted in FIG. 3.On this basis the expansion coefficient f (or the formabilitycoefficient F(r)) may be determined. It will be the best to measuredistribution (Tensile-elongation) in longitudinal and circumferentialdirections simultaneously.

The foregoing expandability coefficient (or formability coefficient) isfound to be useful in predicting good expansion results and may befurther useful when used in combination with one or more otherproperties of a tubular member selected from stress-strain properties inone or more directional orientations of the material, strength &elongation, Charpy V-notch impact value in one or more directionalorientations of the material, stress burst rupture, stress collapserupture, yield strength, ductility, toughness, and strain-hardeningexponent (n−value), and hardness.

In an exemplary embodiment, a tribological system is used to reducefriction and thereby minimize the expansion forces required during theradial expansion and plastic deformation of the tubular members thatincludes one or more of the following: (1) a tubular tribology system;(2) a drilling mud tribology system; (3) a lubrication tribology system;and (4) an expansion device tribology system.

In an exemplary embodiment, the tubular tribology system includes theapplication of coatings of lubricant to the interior surface of thetubular members.

In an exemplary embodiment, the drilling mud tribology system includesthe addition of lubricating additives to the drilling mud.

In an exemplary embodiment, the lubrication tribology system includesthe use of lubricating greases, self-lubricating expansion devices,automated injection/delivery of lubricating greases into the interfacebetween an expansion device and the tubular members, surfaces within theinterface between the expansion device and the expandable tubular memberthat are self-lubricating, surfaces within the interface between theexpansion device and the expandable tubular member that are textured,self-lubricating surfaces within the interface between the expansiondevice and the expandable tubular member that include diamond and/orceramic inserts, thermosprayed coatings, fluoropolymer coatings, PVDfilms, and/or CVD films.

In an exemplary embodiment, the tubular members include one or more ofthe following characteristics: high burst and collapse, the ability tobe radially expanded more than about 40%, high fracture toughness,defect tolerance, strain recovery @ 150 F, good bending fatigue, optimalresidual stresses, and corrosion resistance to H₂S in order to provideoptimal characteristics during and after radial expansion and plasticdeformation.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a charpy energy of at least about 90 ft-lbs in orderto provided enhanced characteristics during and after radial expansionand plastic deformation of the expandable tubular member.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a weight percentage of carbon of less than about0.08% in order to provide enhanced characteristics during and afterradial expansion and plastic deformation of the tubular members.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having reduced sulfur content in order to minimize hydrogeninduced cracking.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a weight percentage of carbon of less than about0.20% and a charpy-V-notch impact toughness of at least about 6 joulesin order to provide enhanced characteristics during and after radialexpansion and plastic deformation of the tubular members.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a low weight percentage of carbon in order to enhancetoughness, ductility, weldability, shelf energy, and hydrogen inducedcracking resistance.

In several exemplary embodiments, the tubular members are fabricatedfrom a steel alloy having the following percentage compositions in orderto provide enhanced characteristics during and after radial expansionand plastic deformation of the tubular members: C Si Mn P S Al N Cu CrNi Nb Ti Co Mo EXAMPLE A 0.030 0.22 1.74 0.005 0.0005 0.028 0.0037 0.300.26 0.15 0.095 0.014 0.0034 EXAMPLE B MIN 0.020 0.23 1.70 0.004 0.00050.026 0.0030 0.27 0.26 0.16 0.096 0.012 0.0021 EXAMPLE B MAX 0.032 0.261.92 0.009 0.0010 0.035 0.0047 0.32 0.29 0.18 0.120 0.016 0.0050 EXAMPLEC 0.028 0.24 1.77 0.007 0.0008 0.030 0.0035 0.29 0.27 0.17 0.101 0.0140.0028 0.0020 EXAMPLE D 0.08 0.30 0.5 0.07 0.005 0.010 0.10 0.50 0.10EXAMPLE E 0.0028 0.009 0.17 0.011 0.006 0.027 0.0029 0.029 0.014 0.0350.007 EXAMPLE F 0.03 0.1 0.1 0.015 0.005 18.0 0.6 9 5 EXAMPLE G 0.0020.01 0.15 0.07 0.005 0.04 0.0025 0.015 0.010

In an exemplary embodiment, the ratio of the outside diameter D of thetubular members to the wall thickness t of the tubular members rangefrom about 12 to 22 in order to enhance the collapse strength of theradially expanded and plastically deformed tubular members.

In an exemplary embodiment, the outer portion of the wall thickness ofthe radially expanded and plastically deformed tubular members includestensile residual stresses in order to enhance the collapse strengthfollowing radial expansion and plastic deformation.

In several exemplary experimental embodiments, reducing residualstresses in samples of the tubular members prior to radial expansion andplastic deformation increased the collapse strength of the radiallyexpanded and plastically deformed tubular members.

In several exemplary experimental embodiments, the collapse strength ofradially expanded and plastically deformed samples of the tubulars weredetermined on an as-received basis, after strain aging at 250 F for 5hours to reduce residual stresses, and after strain aging at 350 F for14 days to reduce residual stresses as follows: Collapse Strength After10% Tubular Sample Radial Expansion Tubular Sample 1 - as received 4000psi from manufacturer Tubular Sample 1 - strain aged 4800 psi at 250 F.for 5 hours to reduce residual stresses Tubular Sample 1 - strain aged5000 psi at 350 F. for 14 days to reduce residual stresses

As indicated by the above table, reducing residual stresses in thetubular members, prior to radial expansion and plastic deformation,significantly increased the resulting collapse strength-post expansion.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a charpy energy of at least about 90ft-lbs.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising a charpy energy of atleast about 90 ft-lbs.

A structural completion positioned within a structure has been describedthat includes one or more radially expanded and plastically deformedexpandable members positioned within the structure; wherein one or moreof the radially expanded and plastically deformed expandable members arefabricated from a steel alloy comprising a charpy energy of at leastabout 90 ft-lbs.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.08%.

An expandable member for use in completing a wellbore by radiallyexpanding and plastically deforming the expandable member at a downholelocation in the wellbore has been described that includes a steel alloycomprising a weight percentage of carbon of less than about 0.08%.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members positionedwithin the wellbore; wherein one or more of the radially expanded andplastically deformed expandable members are fabricated from a steelalloy comprising a weight percentage of carbon of less than about 0.08%.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.20% and a charpy V-notch impact toughness of at least about 6joules.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising a weight percentage ofcarbon of less than about 0.20% and a charpy V-notch impact toughness ofat least about 6 joules.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising a weight percentageof carbon of less than about 0.20% and a charpy V-notch impact toughnessof at least about 6 joules.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising the following ranges of weightpercentages: C, from about 0.002 to about 0.08; Si, from about 0.009 toabout 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 toabout 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04;N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up toabout 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9;and Mb, up to about 5.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising the following ranges ofweight percentages: C, from about 0.002 to about 0.08; Si, from about0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up toabout 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co,up to about 9; and Mo, up to about 5.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising the followingranges of weight percentages: C, from about 0.002 to about 0.08; Si,from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P,from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up toabout 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about0.6; Co, up to about 9; and Mb, up to about 5.

A method for manufacturing an expandable tubular member used to completea structure by radially expanding and plastically deforming theexpandable member has been described that includes forming theexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes an expandable tubular member with a ratio of theof an outside diameter of the expandable tubular member to a wallthickness of the expandable tubular member ranging from about 12 to 22.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members positionedwithin the structure; wherein one or more of the radially expanded andplastically deformed expandable members are fabricated from anexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

A method of constructing a structure has been described that includesradially expanding and plastically deforming an expandable member;wherein an outer portion of the wall thickness of the radially expandedand plastically deformed expandable member comprises tensile residualstresses.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinan outer portion of the wall thickness of one or more of the radiallyexpanded and plastically deformed expandable members comprises tensileresidual stresses.

A method of constructing a structure using an expandable tubular memberhas been described that includes strain aging the expandable member; andthen radially expanding and plastically deforming the expandable member.

A method for manufacturing a tubular member used to complete a wellboreby radially expanding the tubular member at a downhole location in thewellbore has been described that includes forming a steel alloycomprising a concentration of carbon between approximately 0.002% and0.08% by weight of the steel alloy.

It is understood that variations may be made to the foregoing withoutdeparting from the spirit of the invention. For example, the teachingsof the present disclosure may be used to form and/or repair a wellborecasing, a pipeline, or a structural support. Furthermore, the variousteachings of the present disclosure may combined, in whole or in part,with various of the teachings of the present disclosure.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember, comprising: forming the expandable member from a steel alloycomprising a weight percentage of carbon of less than about 0.08%. 2.The method of claim 1 further comprising: forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.20% and a charpy V-notch impact toughness of at least about 6joules.
 3. The method of claim 1 further comprising: forming theexpandable member from a steel alloy comprising the following ranges ofweight percentages: C, from about 0.002 to about 0.08; Si, from about0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up toabout 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co,up to about 9; and Mo, up to about
 5. 4. The method of claim 1 furthercomprising: forming the expandable tubular member with a ratio of the ofan outside diameter of the expandable tubular member to a wall thicknessof the expandable tubular member ranging from about 12 to
 22. 5. Anexpandable member for use in completing a wellbore by radially expandingand plastically deforming the expandable member at a downhole locationin the wellbore, comprising: a steel alloy comprising a weightpercentage of carbon of less than about 0.08%.
 6. The expandable memberof claim 5 further comprising: a steel alloy comprising a weightpercentage of carbon of less than about 0.20% and a charpy V-notchimpact toughness of at least about 6 joules.
 7. The expandable member ofclaim 5 further comprising: a steel alloy comprising the followingranges of weight percentages: C, from about 0.002 to about 0.08; Si,from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P,from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up toabout 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about0.6; Co, up to about 9; and Mo, up to about
 5. 8. The expandable memberof claim 5 further comprising: an expandable tubular member with a ratioof the of an outside diameter of the expandable tubular member to a wallthickness of the expandable tubular member ranging from about 12 to 22.9. A structural completion, comprising: one or more radially expandedand plastically deformed expandable members positioned within thewellbore; wherein one or more of the radially expanded and plasticallydeformed expandable members are fabricated from a steel alloy comprisinga weight percentage of carbon of less than about 0.08%.
 10. Thestructural completion of claim 9 further comprising: one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising a weight percentageof carbon of less than about 0.20% and a charpy V-notch impact toughnessof at least about 6 joules.
 11. The structural completion of claim 9further comprising: one or more radially expanded and plasticallydeformed expandable members; wherein one or more of the radiallyexpanded and plastically deformed expandable members are fabricated froma steel alloy comprising the following ranges of weight percentages: C,from about 0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn,from about 0.10 to about 1.92; P, from about 0.004 to about 0.07; S,from about 0.0008 to about 0.006; Al, up to about 0.04; N, up to about0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb,up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up toabout
 5. 12. The structural completion of claim 9 further comprising:one or more radially expanded and plastically deformed expandablemembers positioned within the structure; wherein one or more of theradially expanded and plastically deformed expandable members arefabricated from an expandable tubular member with a ratio of the of anoutside diameter of the expandable tubular member to a wall thickness ofthe expandable tubular member ranging from about 12 to
 22. 13. A methodfor manufacturing a tubular member used to complete a wellbore byradially expanding the tubular member at a downhole location in thewellbore comprising: forming a steel alloy comprising a concentration ofcarbon between approximately 0.002% and 0.08% by weight of the steelalloy.
 14. The method of claim 13, further comprising forming the steelalloy with a concentration of niobium comprising between approximately0.015% and 0.12% by weight of the steel alloy.
 15. The method of claim14, further comprising: forming the steel alloy with low concentrationsof niobium and titanium; and limiting the total concentration of niobiumand titanium to less than approximately 0.6% by weight of the steelalloy.
 16. An expandable tubular member for use in completing a wellborecompletion within a wellbore that traverses a subterranean formation byradially expanding and plastically deforming the expandable tubularmember within the wellbore, comprising: a steel alloy having a charpyenergy of at least about 90 ft-lbs; a steel alloy having a charpyV-notch impact toughness of at least about 6 joules; and a steel alloycomprising the following ranges of weight percentages: C, from about0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn, from about0.10 to about 1.92; P, from about 0.004 to about 0.07; S, from about0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, upto about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about 5;wherein a ratio of the of an outside diameter of the expandable tubularmember to a wall thickness of the expandable tubular member ranging fromabout 12 to 22; and wherein the expandable tubular member is strain agedprior to the radial expansion and plastic deformation of the expandabletubular member within the wellbore.